Laser Generated Broadband Rayleigh Waveform Evolution for Metal Additive Manufacturing Process Monitoring

This work proposes that laser pulses can generate finite amplitude Rayleigh waves for process monitoring during additive manufacturing. The noncontact process monitoring uses a pulsed laser to generate Rayleigh waves, and an adaptive laser interferometer to receive them. Experiments and models in th...

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Bibliographic Details
Published in:Applied sciences 2022-12, Vol.12 (23), p.12208
Main Authors: Bakre, Chaitanya, Afzalimir, Seyed Hamidreza, Jamieson, Cory, Nassar, Abdalla, Reutzel, Edward W., Lissenden, Cliff J.
Format: Article
Language:English
Subjects:
Additive manufacturing
Aluminum
Amplitudes
Broadband
Energy
Evolution
laser generation
laser interferometer
Lasers
Manufacturing
Manufacturing industry
Metals
Monitoring
nonlinear ultrasonics
Nonlinearity
Process controls
Process parameters
Propagation
Pulsed lasers
Rayleigh waves
Ultrasonic imaging
Velocity
Wave propagation
Waveforms
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Summary:This work proposes that laser pulses can generate finite amplitude Rayleigh waves for process monitoring during additive manufacturing. The noncontact process monitoring uses a pulsed laser to generate Rayleigh waves, and an adaptive laser interferometer to receive them. Experiments and models in the literature show that finite amplitude waveforms evolve with propagation distance and that shocks can even form in the in-plane particle velocity waveform. The nonlinear waveform evolution is indicative of the material nonlinearity, which is sensitive to the material microstructure, which in turn affects strength and fracture properties. The measurements are made inside a directed energy deposition additive manufacturing chamber on planar Ti-6Al-4V and IN-718 depositions. By detecting the out-of-plane particle displacement waveform, the in-plane displacement and velocity waveforms are also available. The waveform evolution can be characterized (i) for one source amplitude by reception at different points or (ii) by reception at one point by applying different source amplitudes. Sample results are provided for intentionally adjusted key process parameters: laser power, scan speed, and hatch spacing.
ISSN:2076-3417
2076-3417
DOI:10.3390/app122312208